Automated Aluminum & Steel Destacking

Solutions

Destacking Introduction

Atlas automated blank destackers handle separated blanks via robots, pick and place shuttles or overhead destack head to mag belts and conveys them forward to a centering station for pick up by press feeding equipment.

Automated blank destackers ensure a continuous flow of blanks to the press. When equipped with a cranesaver conveyor (for queuing stacks), a lift table and a “continuous destacking” carriage, you can achieve non-stop destacking at production rates that range up to 1,320 parts per hour, without a pause in press actuation.

Robotic front of line destacking systems utilize two destacking tables equipped with lifts and an optimally positioned robot (dependant upon floor space and blank sizes). Robots typically offer a lower cost, highly flexible solution with the added benefit of a programmable pathway. Production rates range up to 720 parts per hour.

Both types of destacking systems may incorporate the Atlas Cyclone washer and/or the Atlas Oiler for optimum blank cleanliness and lubrication.

Conventional Destacking…How it Works

The Destack SequenceDuring operation, a palletized stack of blanks is conveyed into position via cranesaver conveyor onto a lift

table. Lift tables are utilized to maintain blanks at a consistent height as the stack is depleted to reduce

destack head travel. Individual blanks are separated by fanner magnets, picked up by overhead vacuum

cups and raised to a magnetic belt conveyor. Magnetic rollers are used in some applications, and systems

can be configured for non-magnetic sheets as well, such as aluminum. The vacuum cups release their

grasp and retract above the belts (or rollers). Each blank is then conveyed through a blank washer and/or

oiler, if additional lubrication is required, and positioned in a gage station, ready to be picked up by first-

press, pick-and-place load automation.

The Continuous Destacking SystemProvides continuous “no interruption” destacking. As a stack

of blanks gets close to depletion, the remaining blanks are

supported by carriage mounted forks that allow the next stack

to be positioned by the conveyor under the destack head. The

lift table raises the stack to right underneath the forks. When

the forks are empty, they retract and the destack head

immediately begins destacking the next stack. Another

strategy employs an indexing destack head that can

alternately access two stacks.

Cranesaver ConveyorAn integrated chain conveyor that queues stacks of blanks,

indexes them into position under the destack head, and moves

empty pallets or dunnage (if used) out after depletion. In-line,

L-shaped, U-shaped and other configurations can be used

depending on available space and number of pallet stations

desired.

Lift Table(a.k.a stack lifter, scissor lift)

The lift table maintains the blanks at a consistent height as the stack is

depleted, reducing the distance the destack head travels to contact each

blank. Straight-acting or scissor lifts are typically used.

Disengageable Fanner Magnets

Fanner magnets separate steel blanks before the destack head contacts the

top sheet for destacking. Fanning the blanks helps to reduce the amount of

double blank rejects entering the reject bin or causing a halt situation. The

“disengageable” feature allows the magnetic field to be broken if you need

to pull the fanner unit away from a stack in order to remove or adjust a

partial stack, or otherwise gain access to it.

Double Blank Detector

(a.k.a. double-sheet detector)

Prevents damage, expense and downtime that can result when more than

one blank is loaded into the press. Sensors detect more than one blank,

and are typically set up to signal the destacker to place blanks that are

stuck together in a reject bin or halt operation.

Scissor Lift Table

Fanner Magnets

Double Sheet Detectors

The Destack Head

Typically a carriage-mounted set of vacuum cups that extend

and retract above and below an inverted magnetic belt or roller

conveyor. The vacuum cups engage a steel blank and raise it

to the conveyor. In non-magnetic applications, the destack

head indexes horizontally and drops the blank onto the

conveyor.

Traversing Head Destacker

Suitable for slower press speeds and non-magnetic blanks.

Eliminates the use of a magnetic belt conveyor. After picking

up the blank, the entire destack head indexes and the blank is

released into a nest or onto an in-feed conveyor.

Vacuum Cups

The primary element of the destack head. Vacuum cups secure

each blank and raise it to a magnetic belt (or roller) conveyor.

They are preferred over magnets because they do not mar

surface finishes. In applications where blank size changes

frequently, individually adjustable vacuum cups and arms (with

easy-access) are employed, coupled with programming features

for activating or de-activating individual cups.

Traversing Head Destacker

Vacuum Cups (a.k.a. pogo sticks) and Overhead Mag Belt Conveyor

Magnetic ConveyorAn inverted conveyor that holds each blank via magnetism and

conveys it horizontally, releasing it in a nest or gage station. Can

convey blanks through a washer and/or oiler. Utilizes either

magnetic belts or magnetic rollers.

Gage Station(a.k.a. crowder, centering station, nesting station, nest)

Manually or automatically adjusted gages that accurately position

the part for press loading after destacking. Our fully

programmable, servo-controlled gages allow fast, automatic 2-

axis adjustment to create the appropriate position for different

blank sizes and shapes.

Press LoaderMoves a single blank, after destacking from the nest (or gage

station) to the press. Dedicated pick-and-place or multi-axis

robots are common, and linear shuttles can also be used. In

transfer press applications, the in-press transfer automation can

pick up the blank right from the nest or gage station.

Overhead Mag Roll Conveyor

Overhead Mag Belt Conveyor

Programmable Gage Station

No Transfer Press Loader Required

In most transfer press applications, the Atlas gage station

configuration eliminates the need for a press loader, since the

destacker is designed to interface with the transfer press

automation for pick up from the gage station by the transfer

fingers or crossbar vacuum cups.

Atlas Command Center Integrated Controls System

PLC or PC based systems monitors and controls destack

operations and can be integrated with press controls.

Advanced destackers have programmable vacuum cups, gage

stations and system diagnostics.

Optional Blank Lubrication

Atlas Technologies spray oiler provides programmed

additional lubrication of blanks. Other features and benefits

include: Individually controlled, self cleaning nozzles, self

contained oil spray tank and mist collector, even distribution

of fluid on the entire blank (both top and bottom) and PLC

controlled spray patterns based on part requirements.

Robotic Destacking

For applications with slower press speeds, robotic

destacking provides a solution that is lower in cost and

high in flexibility. The end of arm tool is utilized to place

the blank either directly into the press, into a centering

station or onto a vision conveyor. As with conventional

destacking, an Atlas Cyclone washer may be utilized for

optimal cleaning and additional lubrication of the blank.

The front of the line may consist of one or two robots

depending on the configuration of the available floor

space and peripheral automation. Commonly, two

destack stations are located side by side with a central

destacking robot. Fixed position destack tables with lifts

are used with manually positioned stack locators that aid

in loading stacks in a repeatable position.

In ferrous metal applications, the separation of the

blanks would be assisted by fanner magnets and in non-

ferrous (aluminum) applications, high powered air knives

are used to separate the materials.

Destacker Installations

Why Atlas?

Our Promise….Atlas listens to you, the customer.

We embrace your vision and understand your motivation.

It’s our culture of total commitment that allows us to conceptualize solutions tailor made to fit your specific applications…creating world class material handling systems that will exceed your expectations.

3100 Copper AvenueFenton, Michigan 48430 USAPhone: +1 810.629.6663Fax: +1 810.629.8145www.atlastechnologies.com

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